Cushion and method of manufacture



1967 J. A. MARSH ETAL CUSHION AND METHOD OF MANUFACTURE 2 Sheets-Sheet 1Original Filed March 19, 1964 INVENTORS ATTORNEYS Aug. 15, 1967 J. A.MARSH ETAL 3,335,435 CUSHION AND METHOD OF MANUFACTURE Original FiledMarch 19, 1964 2 Sheets-Sheet 2 HVVEBHTDRS ATTORNEYS Unite States Patent3,335,435 CUSHION AND METHOD OF MANUFACTURE John A. Marsh and George W.Arrnfield, High Point, N.C., assignors to Marsh-Armfield, High Point,N.C., a corporation of North Carolina Original application Mar. 19,1964, Ser. No. 353,222, new Patent No. 3,283,346, dated Nov. 8, 1965.Divided and this application Mar. 28, 1966, Ser. No. 559,017

8 Claims. (Cl. -355) ABSTRACT OF 1am DISCLOSURE A cushion constructionformed of a resilient, but somewhat stiff backbone member over which isdisposed a batt of loosely matted fibers kept intact by materialcovering opposite sides of the batt. The marginal edges of the batt arepulled over the peripheral edges of the backbone memher and are adheredthereto.

This invention relates to cushions and pillows and intermediate similararticles of manufacture for making upholstered furniture and to methodsfor manufacturing the same. Although the invention will be describedwith reference to cushions and similar intermediate upholsteringarticles especially adapted for use as a seat or a back for upholsteredfurniture, it will be realized that cushions or pillows embodying thisinvention are adapted for other uses.

This application is a division of our copending application Ser. No.353,222, filed Mar. 19, 1964.

Cushions of the type with which this invention is concerned are known inthe art and consist usually of a somewhat stiff resilient core orbackbone, preferably polyurethane, covered on its opposite sides withbatts of crimped Dacron fibers. These batts usually are backed on bothsides with cheesecloth, commonly called scrim, which is attached to thebatts by spaced lines of stitching. The assembly of the core or backboneand batts is enclosed within a cloth cover to form a cushion, whichnormally is then sold as an entirety to furniture manufacturers and isintended to be subsequently covered with upholstery fabric.

Up to the time of the subject development, cushions of the foregoingnature have been assembled by sewing the batts, about their margins, tothe cover. Initially during this sewing operation the cover is insideout and has an opening along one edge. After the batts are sewn to thecover, the latter is turned right side out and the core is insertedthrough the opening between the batts. After the core has been soinserted, the edges of the cover must then be sewn together along theopening.

The foregoing conventional method of assembly not only istirne-consuming because of the sewing operation, but also requires theuse of two different types of sewing machines, one to sew the batts tothe cover, and another to sew together the edges of the cover along theopening. In addition, the Dacron batts must extend beyond the peripheryof the block-like core in order to provide marginal edge portions whichcan be sewn to the cover with lines of stitching that extend along theedge of the cushion. These extended marginal edge portions actually arenonessential in the finished cushion and thus require the use of morebatt material than necessary. Moreover, cushions made by the foregoingmethod have seams that are somewhat bulky.

Additionally, the foregoing mode of assembly results in a product thatis subject to variations in cover tightness because of errors occurringin the sewing operation and also in the operation of cutting the batts.In the event that the cover is too tight, the finished cushion lacks thedesirable soft downy feel. In the event that the cover is too loose, thecushion will be unsightly and lack smoothness because of wrinkles and soforth.

Furthermore, the block or slab-like core in the con ventional typecushion is not positively attached to the cover or to the batts, and,consequently, can shift position or crawl within the cushion and thusdistort it out of shape. The latter problem does not exist in cushionsembodying this invention because all elements of the cushion are securedto each other, i.e., the cover to the core, the cover to the batts, andthe batts to the core.

Accordingly, an object of this invention is to provide an improvedcushion that results in savings of both material and time inmanufacture.

A further object of the invention is to provide an improved cushion thatis not subject to variations in cover tightness and which eliminates thebulkiness of sewn seams.

Still another object of the invention is to provide an improved cushionwherein there is no possibility of the core or backbone becomingdisplaced within the cushion.

Another object of this invention is to provide an improved method ofassembling a cushion of the type described which accomplishes theforegoing objects.

A still further object of this invention is to provide a cushion-likeintermediate article of manufacture for making upholstered furniturethat is inexpensive to manufacture.

Referring now to the drawings forming a part of this specification andillustrating a preferred embodiment of the invention:

FIGURE 1 is a perspective view showing the method embodying thisinvention for assembling the various elements of the cushion;

FIGURE 2 is a perspective view of one of the batts of fibers covered onboth sides with scrim;

FIGURE 3 is a perspective view, partially broken awa of an assembledcushion embodying this invention;

FIGURE 4 is a sectional view taken substantial-1y along the line 4-4 ofFIGURE 3;

FIGURE 5 is a sectional view of a modified type of cushion used as anintermediate article of manufacture;

FIGURE 6 is a perspective view of another modified type of cushion; and

FIGURE 7 is a sectional view taken substantially along the line 77 ofFIGURE 6 Referring now to FIGURES 3 and 4 of the drawings there is showna cushion 10 embodying this invention. The cushion 10, which forexemplary purposes only is illustrated as being generally rightparallelepiped in shape and thus adapted for use as a seat or backcushion for a sofa, a chair, or the like, has a slab-like core orbackbone 12 of greater width and length than thickness. The core 12 isof a resilient yet somewhat stiff material, preferably a syntheticresinous foam, e.g., polyurethane, or material having similarcharacteristics of resilience and stiffness.

The core 12 is interposed between two batts of fibers 14, 14 which aregenerally coextensive with the core. Each batt 14 comprises looselymatted fibers l6 preferably covered on opposite sides with scrim 18. Thescrim 18 is attached to each batt 14 by spaced lines of stitching 2t),

extend beyond the peripheral edges of the batts 14 and batts 14 and core12,

core 12, as seen best in FIGURE 1. After assembly, the marginal edgeportions 24 of the cover parts 22 are folded over each other inoverlapping relation and are bonded to each other by a suitableadhesive. The under or innermost flap 24, and also a portion of theouter flap 24 are bonded by the adhesive to the peripheral edges of thecore 12. Moreover, portions of the flaps 24 are bonded by adhesive tothe peripheral edge of the batts 14, while marginal edge portions of thelatter are also bonded by adhesive to marginal edge portions of the core12. Hence, all elements of the cushion are secured to each other. Whilevarious types of adhesive are suitable, it has been found that anemulsion of latex in water is very satisfactory.

Referring to FIGURE 1, the improved cushion preferably is made bystacking the various elements on a press generally indicated at 28 andhaving a flat bed 30 and a movable top platen 32, in the followingorder: (1) cover part 22, (2) batt 14, (3) core 12, and cover part 22.The assembled elements are compressed vertically, i.e., in a directiontransverse to their planes, by descent of the top platen 32, toprecisely the extent which is desired in the finished product.Preferably the top platen 32 is coextensive with the horizontal outlineof the assembled cushion 10, as shown. While the assembly is thuscompressed, an operator applies adhesive to the peripheral edges of theand to the inner sides of the fiaps 24 of the cover parts 22. Theadhesive may be applied by a brush (not shown) or preferably by a spraygun 34, as shown in FIGURE 1. When using the latter, the marginal edgeportions 24 of the cover parts 22 can be held out to receive theadhesive by the current of air from the gun 34.

After the adhesive has been applied, the operator folds the marginaledge portions 24 of the cover parts 22 into overlapping relation andthey become bonded to each and to the peripheral edges of the batts 14and core 12. Some adhesive also will penetrate and soak between thebatts 14 and the core 12 and thus bond the marginal edges of theseelements together. Because of the foregoing construction, it will beseen that all of the elements of the cushion are secured to each other,i.e., the cover to the core, the cover to the batts, and the batts tothe core. Consequently, the possibility of the core becoming displacedwithin the cushion is eliminated. Additionally, the method of assemblyprovides for a precisely controlled degree of covertightness.

It is to be understood that although the invention has been illustratedand described with reference to a cushion generally in the shape ofright parallelepiped, which may be termed rectangular, the invention isequally applicable to cushions of other shapes, e.g., round, oval, etc.Furthermore, it will be seen that by omitting a batt from one side ofthe core a cushion can be constructed, in the same manner asaforedescribed, that can be used for What is usually called asemi-attached cushion, i.e., one wherein the cushion, although made as aseparate unit, is subsequently sewn to the back of a piece ofupholstered furniture.

FIGURE illustrates a simplified modification of the cushion shown inFIGURES 3 and 4 that can be used as a cushion-like intermediate articlein making upholstered furniture.

Referring now to FIGURE 5, the core 36 is interposed between two battsof fiber 38, 38 that are cut to have substantially the same or slightlylarger size peripheral outline as the core. Each batt comprises looselymatted fibers covered on opposite sides with scrim 49 made of the samematerial as previously described. After assembly, the marginal edgeportions 42 of the top layer of scrim of the top batt, and the bottomlayer of scrim of the bottom batt, are stretched and pulled over theperipheral edges of the core and bonded thereto by a suitable adhesiveor cement. Moreover, marginal edge portions of the fibrous portion ofthe batts 38, as well as the crim 40, are also bonded by adhesive tomarginal edge portions of the core 36. Hence, all elements of thecushion are secured to each other. In this connection, the scrim orcheesecloth is sufficiently stretchy so that it can be pulled andstretched as aforesaid to provide a product wherein the outer surface ofthe opposite sides of the cushion is relatively tight. If desired, oneof the batts can be omitted to provide a semiattached cushion.

A still further modified embodiment of the invention is shown in FIGURES6 and 7, indicated generally as 44, Here, as best seen in FIGURE 7, abatt 46 covered on opposite sides with scrim 48 is first cut to aperipheral outline considerably larger than that of a backbone or core50 of polyurethane. The batt 46 is then placed to overlie the front face52 of the core 50 and the overhanging marginal edges of the batt arewrapped around all four peripheral edges of the slab-like backbonemember 50 and bonded to the back face 54 of the backbone member 50, nearthe marginal edges thereof, by an adhesive. Additional bonding strengthmay be provided by applying tape 56 to overlie the marginal edge portionof the batt 46 and the adjacent exposed surface of the back face 54. Allof the elements of this article preferably are of the same material asthe cushion shown in FIGURES 3 and 4.

The intermediate cushion-like articles of manufacture shown in FIGURES 5and 6 can be enclosed in upholstery fabric in a conventional manner, andthen used for upholstery purposes. The semi-attached article wherein oneof the batts is omitted can be secured in conventional fashion to theback of an upholstered piece of furniture, and subsequently covered withupholstery fabric. The article shown in FIGURE 6 is used where a morerounded appearance is desired.

Although articles of the type shown in FIGURES 5 and 6 are not asfinished in appearance as a cushion which is provided With a fabriccover, e.g. FIGURE 3, they are less expensive to make and will sufficefor certain purposes of manufacturers of upholstered furniture. In thisconnection, it will be realized that a simple cushion of the aforesaidtype also can be made in a variety of shapes and sizes.

It will be realized that a manufacturer of upholstered furniture couldeliminate individual cushions and inner springs, simply secure, to theback or seat of the furniture piece, a polyurethane base element whichhas a batt of Dacron fibers secured thereto by cement as aforedescribed.In this case, the core of polyurethane would have to be made thickenough to take the place of omitted coil springs.

The method of manufacturing the articles shown in FIGURES 5 and 6obviously is similar to the method described above for a cushion havinga two-part cover. In the case of the article shown in FIGURE 5, theplatens used to compress the backbone member 36 and the batt 38assembled in overlying relation must be sufficiently smaller incross-sectional area than the batt to enable the marginal edge portions42 of the scrim on the outer sides of the batt to be pulled intooverlapping relation with the peripheral edge potrion of the backbonemember. Also, in compressing the assembled backbone member 50 andoverlying batt 46 shown in FIGURES 6 and 7, the platen used to compressthe back face 54 of the backbone member must be of smaller outline thanthe backbone member to permit the marginal edge portions of the batt tooverlie and. be cemented to the marginal edge portions of the back faceof the backbone member and to permit adhesive tape to be applied inoverlying relation with the marginal edge portion of the batt and theadjacent exposed areas of the backbone member.

Although specific embodiments of the invention have been shown toillustrate the principles of the invention, it should be clear that manymodifications can be effected that do not depart from these principlesand therefore this invention should be limited only by the spirit andscope of the following claims.

What is claimed is:

1. A cushion-like intermediate article of manufacture for use in makingupholstered furniture comprising: a slab-like backbone member ofresilient but somewhat stiff material; at least one batt ofloosely-matted fibers, having scrim secured to the opposite sidesthereof, said batt being disposed in overlying relation with one side ofsaid member and generally coextensive therewith, when relaxed, themarginal edge portions of the scrim on the outer side of said batt beingpulled outwardly and folded against the peripheral edges of said member;and an adhesive bonding said marginal edge portions to said peripheraledges of said member.

2. The structure defined in claim 1 wherein the adhesive bonds themarginal edge portions of the batt to the peripheral edges of thebackbone member.

3. A cushion-like intermediate article of manufacture for use in makingupholstered furniture comprising: a slab-like backbone member ofresilient but somewhat stiff material; batts of loosely matted fibershaving scrim secured to the opposite sides thereof; said batts beingdisposed in overlying relation with the opposite sides of said memberand generally coextensive therewith, when relaxed, the marginal edgeportions of the scrim on the outer sides of said batts being pulledoutwardly and folded against the peripheral edges of said member; and anadhesive bonding said marginal edge portions to the peripheral edges ofsaid member.

4. The structure defined in claim 3 wherein the adhesive bonds themarginal edge portions of each batt to the peripheral edges of thebackbone member.

5. A cushion-like intermediate; article of manufacture for use in makingupholstered furniture comprising: a slab-like backbone member ofresilient but somewhat stiff material; a batt of loosely matted fibershaving scrim secured to the opposite sides thereof; peripheral outlineof said batt being substantially larger than that of said backbonemember and said batt being disposed in overlying relation with one sideof said member with marginal edge portions of said batt being Wrappedabout the peripheral edges of said member and disposed in overlyingrelation with peripheral edge portions of the other side of said member;and an adhesive bonding said marginal edge portions of said batt to theunderlying marginal edge portions of the other side of said member.

6. The structure defined in claim 5 including flexible tape adhesivelysecured to the outer side of the marginal edge portions of the batt andto the adjacent exposed area of the other side of said member.

7. An article of manufacture for use in making upholstered furniturecomprising: a slab-like backbone member of resilient but somewhat stiffmaterial; at least one batt of loosely matted fibers having scrimsecured to the opposite sides thereof, the peripheral outline of saidbatt being at least as large as that of said backbone member and saidbatt being disposed in overlying relation with one side of said member,the marginal edges of at least one of the batt and the scrim beingpulled over the pe ripheral edges of said member; and an adhesivebonding marginal edge portions of said scrim to said member.

8. An article of manufacture for use in making upholstered furniturecomprising:

a slab-like backbone member of resilient but somewhat stilf material; atleast one batt of loosely matted fibers covered on opposite sidesthereof by means for keeping the batt intact, the peripheral outline ofsaid batt being at least as large as that of said backbone member andsaid batt being disposed in overlying relation with one side of saidmember, the marginal edges of the batt being pulled over the peripheraledges of said member; and an adhesive bonding marginal edge portions ofsaid batt to said member.

References Cited UNITED STATES PATENTS 2/1942 Nachman 5-351 3/1963 Ward297 452 3,118,153 1/1964 Hood 5345 3,173,159 3/1965 Hart 5-351 CASMIR A.NUNBERG, Primary Examiner.

1. A CUSHION-LIKE INTERMEDIATE ARTICLE OF MANUFACTURE FOR USE IN MAKINGUPHOLSTERED FURNITURE COMPRISING: A SLAB-LIKE BACKBONE MEMBER OFRESILIENT BUT SOMEWHAT STIFF MATERAIAL; AT LEAST ONE BATT OFLOOSELY-MATTED FIBERSM HAVING SCRIM SECURED TO THE OPPOSITE SIDESTHEREOF, SAID BATT BEING DISPOSED IN OVERLYING RELATION WITH ONE SIDE OFSAID MEMBER AND GENERALLY COEXTENSICE THEREWITH, WHEN RELAXED, THEMARGINAL EDGE PORTIONS OF THE SCRIM ON THE OUTER SIDE OF SAID BATT BEINGPULLED OUTWARDLY AND FOLDED AGAINST THE PERIPHERAL EDGES OF SAID MEMBER;AND AN ADHESIVE BONDING SAID MARGINAL EDGE PORTIONS TO SAID PERIPHERALEDGES OF SAID MEMBER.